Rigidizable insertion tool

Abstract

A rigidizable insertion tool includes a first segment having a pin extension and a second segment having a pin slot that is elongated. The first segment and the second segment are connected via a joint comprising the pin extension of the first segment and the pin slot of the second segment. The pin extension is movable between a proximal end and a distal end of the pin slot with movement of the first segment relative to the second segment.

What is claimed is: 
     
         1 . A rigidizable insertion tool comprising:
 a first segment having a pin extension; and   a second segment having a pin slot that is elongated along a length of the second segment;   wherein the first segment and the second segment are connected via a joint comprising the pin extension and the pin slot, the pin extension being movable between a proximal end and a distal end of the pin slot with movements of the first segment relative to the second segment;   wherein in a non-rigidized state of the joint, the first segment is configured to pitch relative to the second segment via a rotation of the pin extension within the pin slot; and   wherein when a force is applied to push the first segment and the second segment together, the pin extension is moved toward the proximal end of the pin slot, and features of the first segment and the second segment are engaged to limit relative movement between the first segment and the second segment.   
     
     
         2 . The tool of  claim 1 , wherein the pin extension is attached to a first protrusion of the first segment and the pin slot is formed within a first recess of the second segment. 
     
     
         3 . The tool of  claim 2 , wherein the pin extension has two ends and the pin slot comprises a first opening on a first wall of the first recess and a second opening on a second wall of the first recess for receiving the two ends of the pin extension;
 wherein a width of the pin extension from end to end is greater than a distance between the distal end of the first opening and the proximal end of the second opening.   
     
     
         4 . The tool of  claim 1 , wherein the pin extension is formed within a recess of the first segment and the pin slot is formed on a protrusion of the second segment. 
     
     
         5 . The tool of  claim 1 , wherein the features comprise a first protrusion and a first recess that are configured to engage when the force is applied to push the first segment and the second segment together, and
 wherein when the first protrusion and the first recess are engaged, linear movement, pitch, yaw, and/or roll of the first segment relative to the second segment are limited by contacting walls of the first protrusion and the first recess.   
     
     
         6 . The tool of  claim 5 , wherein the first segment and the second segment further comprise a second protrusion and a second recess configured to engage the second protrusion when the force is applied. 
     
     
         7 . The tool of  claim 6 , wherein the second protrusion is tapered at a distal end and the second recess is tapered toward a proximal end such that the first segment is configured to yaw relative to the second segment with at least a portion of the second protrusion inside the second recess. 
     
     
         8 . The tool of  claim 1 , wherein the pin extension is tapered at one or both ends. 
     
     
         9 . The tool of  claim 1 , wherein the pin extension is cylindrical with a circular or elliptical cross-section. 
     
     
         10 . The tool of  claim 1 , wherein the first segment is configured to pitch relative to the second segment with an angular displacement of up to 150 degrees. 
     
     
         11 . The tool of  claim 1 , wherein a distance between the proximal end and the distal end of the pin slot is at least five times greater than an effective diameter of the pin extension. 
     
     
         12 . The tool of  claim 1 , wherein, in the non-rigidized state, the pin extension is configured to pivot relative to a width of the pin slot within the pin slot, such that the first segment is configured to yaw relative to the second segment. 
     
     
         13 . The tool of  claim 1 , wherein at least 70% of a width of the pin slot is at least 0.3 mm greater than an effective diameter of the pin extension. 
     
     
         14 . The tool of  claim 1 , wherein, in the non-rigidized state, the pin extension is configured to rotate around an axis perpendicular to a width of the pin extension within the pin slot, such that the first segment is configured to roll about the axis relative to the second segment. 
     
     
         15 . The tool of  claim 1 , wherein the first segment is configured to roll relative to the second segment with an angular displacement of up to 15 degrees. 
     
     
         16 . The tool of  claim 1 , wherein the pin slot is tapered toward the distal end and limits a rotation of the pin extension when the pin extension is at the distal end of the pin slot. 
     
     
         17 . The tool of  claim 1 , further comprising: a plurality of additional segments each having a pin extension and/or a pin slot. 
     
     
         18 . The tool of  claim 1 , further comprising: a spring coupled between the first segment and the second segment for asserting a counterforce for pushing the pin extension away from the proximal end of the pin slot in the non-rigidized state. 
     
     
         19 . The tool of  claim 1 , further comprising a line assembly configured to apply the force, wherein the first segment and/or the second segment comprises a line guide through which the line assembly is inserted. 
     
     
         20 . A method of forming the rigidizable insertion tool of  claim 1 , comprising:
 forming the first segment and the second segment with additive manufacturing according to a computer model that arranges the first segment and the second segment with a gap between the pin extension and the distal end, and between the pin extension and the proximal end of the pin slot,   wherein the pin extension is formed within the pin slot during the additive manufacturing.